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Corrosion Resistant Alloys (CRAs) and issues of welding, fabrication, and assessment in oil and gas production. Environmentally assisted cracking. Technology gaps impacting the industry.
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For many corrosion-resistant alloys (CRA´s), crevice corrosion under gaskets, paint or O-rings required to define the exposed area and avoid solution contact with electrical connections interferes with measurements of the critical pitting potential (EPIT). This undesired and uncontrolled crevice corrosion occurs at a lower potential than the one for the onset of pitting corrosion. Many approaches have been used to avoid this artifact.
Saline Water Conversion Corporation (SWCC) is the largest producer of water by its different water desalination plants distributed around the kingdom. In SWCC above storage tanks (ASTs) have the capacity to store 140,000 m3 of produced water. Most tanks are commissioned more than 20 years and have worked properly with minor observations on their performance. Mostly SWCC tanks are made of carbon steel and internally protected with a two - components epoxy coating as a passive method and cathodic protection as an active method.
By selection of proper base metal/weld metal combinations and diligent use of established cladding procedures a very serviceable and reliable “wallpaper” metallic lining requiring only periodic cleaning, can be achieved at an economical price.
The use of Duplex Stainless Steels (DSS) in refinery sour environments is governed by ANSI/NACE MR0103/ISO 17945NACE “Metallic materials resistant to sulfide stress cracking in corrosive petroleum refining environments” which limits DSS base materials to be used in Hydrogen Sulfide (H2S) services to a maximum hardness of 28 HRC for materials with a PREN ≤ 40 and to a maximum hardness of 32 HRC for those materials with PREN > 40.1 These hardness values are in line with the hardness requirements of solution annealed as produced straight tubes, but when the heat exchanger design requires the use of integral finning or u-bend tubes, these are subject to significant work hardening that results in as bent and as finned heat exchanger tubes with hardness measurement as high as 418 HV0.5 or 35.6 HRC which clearly exceeds the allowable limits stated above.
Materials qualification testing of corrosion resistant alloys (CRAs) typically involves the use of simple pass/fail tests. Modification of existing standards is recommended for environments in which pit initiation is statistically improbable but pit propagation is rapid, e.g. low chloride/high H2S.
As environmental sulfur limits become more stringent, there has been a recent surge in preferential and localized corrosion in amine units. This has occurred even with HIC (Hydrogen Induced Cracking) resistant steels and in equipment where velocity limits are not exceeded.Amine absorbers and associated rich amine piping particularly around the welds, downcomers and other turbulent locations are particularly vulnerable.